Scribd
Upload
17 views22 pages

Flexural Frame Report

Uploaded by

ashraf.hameed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
17 views22 pages

Flexural Frame Report

Uploaded by

ashraf.hameed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 22

Flexural Testing Apparatus

Modeling
This report is to explain making process of scaled down model for flexural testing
apparatus that used in structural engineering laboratory at civil engineering
department/university of Baghdad>

By: Eng. Mohanned H. Al-Obaidy


Contents
1 Life size apparatus description (Prototype) ......4
1.1 Structural Frame ..........................................4
1.2 Loading system ............................................5
1.3 Stress-Strain measuring accessories ..........5
2 Modeling............................................................5
2.1 Scaling..........................................................5
2.2 Digital model ................................................5
2.3 Physical model .............................................6
2.4 Material ......................................................17
2.5 Loading system simulation.........................18
1 Life size apparatus description (Prototype)
The apparatus was locally manufactured (built up) by civil engineering
dept. professors for research and testing purposes
1.1 Structural Frame
The frame is shown in Figure 1,its 6m in length,2.8m in width and its
height is 3m.

Figure 1

The structural frame consists of I shaped steel member with relatively


large cross section dimensions, members are connected to gather by
steel bolts and welding in some areas.
Bracing members is used at the upper corner of (in-plane) frame to
prevent excessive side sway that may be occurs at testing time resulting
from reaction forces. Or ground motion.
Frame is directly supported on the concrete ground which is carrying no
loads except self-weight of the structural steel frame and some of
loading system parts.
Applied testing load is at self-equilibrium, so no extra reaction (load
carrying capacity) needed from the underneath concrete ground.
1.2 Loading system

1.3 Stress-Strain measuring accessories


strain is measured to determine the level of stress on the material, many
types of strain measuring devices can be used like the mechanical strain
gauge (dial gauge), foil or electrical strain gauge and displacement
transducers (LVDT).

2 Modeling
2.1 Scaling
A Scale of 1:10 was adopted for modeling the apparatus because of its
relatively large dimensions, for steel members cross section dimension
some correction (out of scale) was applied to be 3D printed, however too
thin member’s web or flange cannot be printed.
2.2 Digital model
At first a digital model for the apparatus is constructed using Autodesk
Revit software as shown in Figure 2.
Figure 2

Members are measured and drawn at life size dimension, some


members and connection details cannot be drawn in the model but
measured and printed directly.

Each member is remodeled separately with the scaled down dimension


to allow for exporting in STL file extension that is used by the 3D printer
software, also saving members individual files as reference to be used
later if needed.

2.3 Physical model


The model is 600 X 300mm in dimension with all over height of 350mm
sitting on hollow rectangular shape card board box that contain hydraulic
system power and control. Figure 3 and Figure 4
Figure 3
Figure 4
All members have been named with specific code for scheduling the
printing process and quantities as shown in Figure 6 and Figure 5

Figure 5
Required
No. Member Code Printing Time / Quantity
Item
1 G 1 (Part 1) 12 h 4
2 G 1 (Part 2) 15 h 4
3 G2 13 h 2
4 G3 10 h 2
5 G5 10 h 2
6 G6 4h 4
7 C1 16 h 4
8 B1 25 h 3
Figure 6

Member (G1) is the tallest member with a scaled down length of


490mm which exceeds 3D printer largest dimension, so this member is
broken into two parts. First part with the half length of original member
and extended length of flanges, the second part with the half original
length and extended length of web. That is to inter connect the two parts
strongly (using epoxy resin) and avoiding the connection plane to be in
the mid length of member which experience highest flexural moments.
The two inter connected parts of (G1) member are shown in Figure 7.
Figure 7

Parts after printing may have some imperfections or defects or


sometimes the whole printing process fails so its to be reprinted again,
Figure 8 shows printing process.
Figure 8

For some acceptable imperfections parts are to be treated by sanding


paper with two stages using coarse then fine sanding paper, washing
and drying the member after sanding to get smooth clean surface that is
ready to apply fiber paste (same used for car body repairing) to cover
the printing defects.
After the fiber paste sets members are re-sanded with fine sanding
paper to be ready for painting stage, Figure 9 and Figure 11 shows the
process.
Figure 9

Stiffeners for some members (such as B1 Box girder) cannot be printed


with the member as a one unit, because members are being printed
vertically as Figure 8 in to get advantage of printer’s Z axis with is largest
dimension, in this way stiffeners will be printed horizontally which needs
printing support beneath each one, that takes more printing time and
resulting in bad finish for member’s surface.
Instead, stiffeners are printed separately and assembled on members
using fast setting glue, see Figure 10.
Figure 10
Figure 11

All member are to be painted after printing or after being treated, oil
based yellow paint is used to get a unified color and finish for all
members.
Two or maybe three coats of paint are applied for members to have a
clear consistent surface that simulate the real steel painted members
Figure 12.
Figure 12

For the bolt holes, members are drilled using small size steel drill bit with
3D printed member end plate template used as a guide for holes
spacing and location as in Figure 13.
Some members drilled before painting and others drilled after.
Figure 13

Members are joined together using small diameter steel bolts with nuts
to simulate the real steel connections between members, see Figure 14.
Figure 14

2.4 Material
The general material used in making model’s parts is plastic called PLA
that is specified for 3D printers.
Polylactic Acid (PLA) filament is a recyclable, natural thermoplastic
polyester that is derived from renewable resources such as corn starch
or sugar cane. The filament is biodegradable under certain conditions
with high heat capacity and high mechanical strength. It can be melted
without significant damage and does not emit toxins or fumes.
Typical properties for molded PLA test specimen are as follows:

• Tensile Strength: 38 - 47.8 MPa


• Tensile Modulus: ≅ 4,200 MPa
• Elongation at Break: 41.3 - 63.8%
• Elongation at Yield: ≅ 2.00%
• Flexural Strength: ≅ 85 MPa
• Flexural Modulus: ≅ 3,280 MPa
• Glass Transition Temp: ≅ 53 °C
• Heat Deflection Temp (1.8 MPa): ≅ 60 °C
• Hardness: ≅ Shore D 66
• Density: 1.08 - 1.12g/cc
• Impact Strength (Un-notched) IZOD (J/m) ≅ 96.1
There are many different plastic materials available for 3D printing,
PLA filament is used for the model because it satisfies physical and
economical aspects.
2.5 Loading system simulation
Simple hydraulic loading system is assumed to be simulated, model
system consisting of same general main parts as real system like the
hydraulic pump, piston and cylinder .Figure 15.

Figure 15

Air is used as a hydraulic fluid for the system due to simplicity and to
avoid oil leakage in joints and gaskets in case of liquid hydraulic fluid.
Hydraulic cylinder and tubing modeled from locally available medical
consumables in pharmacies like infusion set and injection syringe
Figure 16 and Figure 17.

Figure 16
Figure 17

The control valve made of combined injection syringe rubber with some
modification, containing one input from pump and two outlets to cylinder
and piston. Valve derived by 3D printed manually shifted lever that’s
control loading or unloading conditions. Figure 18.
Figure 18

Air is pumped to the system continuously by small size 12 volt electric


diaphragm compressor that produce 10 L/min. Air flow, see Figure 19.
Figure 19

You might also like